Apparatus for forming a batch of concrete panels

ABSTRACT

An apparatus for casting slabs of settable material, in which vertically disposed shuttering boards are secured together in spaced horizontal relation to form batches, the batches being passed along a conveyor through a pouring station, in which the settable material is poured between the boards, and a setting station to a deshuttering station in which the batches are dismantled to release the cast slabs for removal. The invention also includes arrangements for returning shuttering boards individually from the deshuttering station to the start of the conveyor through a cleaning and preparatory station.

Un1ted States Patent 1191 1111 3,859,021

Kleiber 1 1 Jan. 7, 1975 [54] APPARATUS FOR FORMING A BATCH OF 2,583,842 1/1952 Hendrickson 249/144 CONCRETE PANELS 3,030,688 4/1962 Tumey 249/79 3,220,692 11/1965 Eklund 249/120 X Inventor: Armin r, Karlsrube, Germany 3,245,129 4/1966 Entz 425/404 3,344,492 10/1967 Eggeling et a1... 425/404 [73] Ass'gnee' y i g GmbH 3,384,939 5/1968 Baker 425/404 at many 3,448,496 6/1969 Arnold 6141 164/340 [22] il F 20 1973 3,465,396 9/1969 Hummelshoj 425/441 [21] Appl' 333508 Primary Examiner-Robert D. Baldwin Related U.S. Application Data Assistant Examiner 1ohn McQuade [62] Division of 581. NO. 107,941, Jan. 20, 1971, Attorney, g or FirmWender0th, Lind & Pnnack abandoned.

[30] Foreign Application Priority Data [57] ABSTRACT Feb. 10, 1970 Germany 2005899 An apparatus for casting slabs of settable material, in

which vertically disposed shuttering boards are se- [52] U.S. Cl 425/186, 249/120, 249/129, cured together in spaced horizontal relation to form 425/88, 425/432, 425/441, 425/456 batches, the batches being passed along a conveyor [51] Int. Cl B28b 1 /08 through a pouring station, in which the settable mate- [58] Field of Search 264/71, 72, 334, 336; rial is poured between the boards, and a setting station 425/88, 121, 182, 183, 186, 253-255, 261, to a deshuttering station in which the batches are dis- 375,424, 434, 451, 432, 452, 456, 441, 129, mantled to release the cast slabs for removal. 161; 249/120 791 81; 259/72 The invention also includes arrangements for 43 returning shuttering boards individually from the deshuttering station to the start of the conveyor [56] References C'ted through a cleaning and preparatory station.

UNITED STATES PATENTS 2,299,019 10/1942 Howe 425/253 5 11 Drawmg F'gures PATENTED JAN 71975 SHEET 2 BF 6 III PATENIEDJAN ms.

SHEET 30F 6.

PATENIEDJAH 1915 I SHEET 8 [IF 6 FIG.1O

FIG. 11

APPARATUS FOR FORMING A BATCH OF CONCRETE PANELS This is a division, of application Ser. No. 107,941, filed Jan. 20, 1971 now abandoned.

BACKGROUND OF THE INVENTION The invention relates to apparatus for producing slabs of castable setting material, particularly concrete, in which apparatus a plurality of slabs are cast side-byside and are removed from the apparatus after setting.

Various constructions of shuttering sets are known for simultaneous production of a number of concrete slabs. These sets consist mainly of a fixed vertical main support board which is firmly connected to a base and of a series of vertical intermediate boards which can be moved on rollers running on overhead longitudinal carriers, for the purpose of opening and closing the set. At the other end of the series of intermediate boards, a movable end board takes up the pressure and the stresses occurring during setting.

The concrete slabs are cast by filling the gaps between the boards with concrete, and the slabs are deshuttered after they have set. Shuttering sets of this kind steam for a large amount of manual work, and the preparatory work in particular, has to be carried out in cramped conditions. Particular difficulties arise during the production of complicated heavily reinforced slabs, for which, the preparation prior to casting requires two to three times the amount of time needed to prepare simple slabs. Also, a number of vibrators have to be fitted on the boards for the purpose of consolidating the poured concrete, so that in the case of a shuttering set producing ten slabs for example, an uneconomically large number of vibrators, about thirty, are required. Oil or stem heating elements are also difficult to incorporate due to the fact that the intermediate boards are displaceable and the supply lines required thus also have to be movable. Thus, with the known shuttering sets, only one full production operation per day can generally be achieved, since most of the shift period is required for preparation work and for the setting of the cast concrete.

SUMMARY OF THE INVENTION It is among the objects of the present invention to provide apparatus for producing slabs of castable setting material, particularly concrete, which, while being of simple overall construction, enables work to be carried out in a more rapid sequence and permits greater accessibility during the preparatory work.

An important aspect of this mode of operation is the forming of batches which pass to a pouring station, or for which a casting station is formed by displaceable vibrating means, so that the batch either moves between the batching station and the pouring station, or the stations are interchangeably used as the batching and pouring station.

In this system it may be expedient to arrange the batches of shuttering boards on the conveyor track in such manner that the direction of travel extends parallel to the surface of the shuttering boards (longitudinal travel). In another advantageous arrangement, the batches of shurttering boards are so arranged on the conveyor track that the direction of travel extends at right-angles to the surface of the shuttering boards (transverse travel).

In another aspect the invention provides apparatus for the batch production of cast slabs, comprising a plurality of shuttering boards, a conveyor, means at the start of the conveyor for forming the shuttering boards into batches, with the shuttering boards in each batch being disposed vertically in spaced horizontal relation, means at apouring station for pouring settable material into batches moved sequentially along the conveyor, and vibratory means for vibrating the batches at the pouring station. The conveyor further comprises a setting zone for batches moved along the conveyor from the pouring station, and a deshuttering station for dismantling each batch after the settable material has set so as to release the cast slabs for removal.

The conveyor track for the batches may expediently take the form of an overhead track consisting of two parallel rails, each shuttering board having at its two sides roller runners for engagement in these rails for the purpose of transverse travel, and, furthermore, the two outermost shuttering boards being connectible to releasable anchoring elements. These latter can be flaptype anchoring means for example.

In contrast to this arrangement for transverse movement, longitudinal movement can optionally and advantageously be carried out in apparatus in which the overhead track likewise consists of two parallel rails in which transverse carriers fitted with rollers engage, and in which apparatus the shuttering boards can be suspended from these transverse carriers, the two outermost shuttering boards again carrying releasable anchoring elements for connection purposes and for providing mutal support.

The conveyor track on which the batch is moved when changing from one station to another can not only take the form of an overhead track, but can also be constructed in another known manner involving the use of floor tracks, cable lines or the like. In another advantageous arrangement, rollers or the like can be fitted to the bottom surfaces of the shuttering boards so that the boards can then be brought together to form a travelling batch.

In the linear mode of operation involving travel of the batches from the batching station, through the pouring station, to the deshuttering station, it may be expedient to dispose a setting tunnel between the casting station and the deshuttering station, which tunnel may be heated by steam, oilburners or electric heating elements.

An additional advantage can be achieved with such apparatus in some circumstances by connecting the deshuttering station to the batching station by means of a linear conveyor system on which the shuttering boards can be individually moved over a path parallel to the shuttering face, this linear conveyor system forming a processing line on which the used shuttering boards can be treated prior to their being brought again to the batching station. Thus, whereas the shuttering boards travel in batches on the conveyor track, i.e., generally between the batching station, pouring station and deshuttering station, these batches are split up in the shuttering station and the shuttering boards are returned separately one behind the other along a processing line to the batching station. In this way, there are provided particularly readily accessible work areas which can be fully utilized for production purposes and in which the cleaning and oiling of the shuttering boards as well as the mounting of reinforcing elements,

,be retained for some time. This means that the sequence of shuttering boards travelling back to the batching station can be optionally interrupted by moving out shuttering boards which require a longer time for their treatment. Such conveyor means can likewise advantageously take the form of overhead rails; other known forms are however possible. To provide for the required periods of dwell, it appears expedient to arrange, parallel to the overhead rails, at least one track to which the shuttering boards can be caused to travel by means of track-switch means or the like. Movement by manual means of the suspended shuttering boards can also be rendered easier by inclining the overhead rail between the deshuttering station and the batching station to an extent that enables the suspended boards to be moved along by hand.

Generally, the conveyor track, constituted by overhead rails, and the conveyor means for the shuttering board treatment line will operate at the same rhythm. Switched boards are preferably removed close to the ground, so that it not necessary to use hooks located at any great height.

For the purpose of turning the shuttering boards, it may be expedient to provide swingable cross-members in the batching station and/or in the deshuttering station, which cross-members can be swung from an angular position of the shuttering boards suspended therefrom, at right-angles to the direction of movement along the overhead track and parallel to the direction of movement in the conveyor means constituting the shuttering-board processing line. In one simple expedient arrangement, swingable rail portions or a curve in the rails are provided at the ends of the processing track. A further advantage can be achieved if required by providing a 90 curve on a conveyor track near the deshuttering station for when the shuttering boards are travelling in the transverse direction, so that the arriving shuttering boards are turned through 90 and are then disposed parallel to the line on which they are processed. This can facilitate turn-round between the conveyor track and the conveyor means.

It may also be expedient for the conveyor track to incorporate, near the pouring station, a section that can be lowered in such manner that the batches of shuttering boards can be deposited on a shaking platform connected to the vibrating means. In another advantageous arrangement, a vertically movable shaking head, connected to the vibrating means, is provided near the pouring station, which shaking head can be moved up to bear on the base of the batch located in the pouring station. This then makes it unnecessary to lower the batches.

A further improvement can be achieved if required by connecting the extensible supporting elements, which take the form of backing members that can be applied to the sides of the batch of shuttering boards, directly to the vibrating means.

In the initially described mode of operation involving change of stations, the vibrating means can be adapted to travel along the batches of shuttering boards suspended from the overhead track and to constitute the vibrating and pouring station by being connected to each batch. In this arrangement, the vibration means is expediently formed as a frame part which can be raised from the floor or lowered from above and which embraces a batch of shuttering boards and, with the aid of extensible support elements, forces it into connection with the vibrating means. These extensible support elements thus perform the double function of providing static reinforcement and transmitting the vibrations. The extensible supporting elements are preferably fitted on all four sides of the frame.

The conveyor track and the conveyor means can, if required, preferably take the form of a common circular track.

To avoid the use of movable connections for electric current, steam or the like, it may be expedient to provide the shuttering boards with heating passages which are open at at least one end and into which the gaseous heating medium in the setting tunnel can readily pass and thus improve the heating action.

Apparatus of this kind involving production of the slabs on a circular path offers all the advantagesof a true assembly line, particularly those of stationary work areas that are properly adapted to technical requirements. The apparatus, together with the preparation areas, can be accommodated in a factory bay of releatively simple construction and having a low roof. Furthermore, the apparatus is suitable for building on point foundations, and can therefore be used in a plant set up on large building sites. The equipment can be extended from a simple initial stage at any time.

BRIEF DESCRIPTION OF THE DRAWINGS Embodiments of the subject-matter of the invention are illustrated schematically in the drawing, in which:

FIG. 1 is a side-view of one embodiment in accordance with the invention,

FIG. 2 shows a plan view of the apparatus shown in FIG. 1,

FIG. 3 is a side view of a second embodiment of the invention,

FIG. 4 is a plan view of the embodiment shown in FIG. 3,

FIG. 5 shows vibrating means with a frame part which embraces a batch of shuttering boards and which can be raised,

FIG. 6 shows a shuttering board containing heating ducts,

FIG. 7 illustrates a pouring and shaking station comprising a portion that can be lowered, and

FIG. 8 shows a pouring station with a liftable shaking head, and

FIGS. 9-11 illustrate the assembly of the shuttering boards into batches.

DETAILED DESCRIPTION OF THE INVENTION In the embodiment shown in FIGS. 1 and 2 there can be seen a batching station I, a pouring and vibrating station II, a setting station III in which the batches have a normal period of dwell of between 4 and I0 hours, and a deshuttering station IV. the shuttering boards, made up into batches l, 2, 3, 4, 5, 6 and 7, are moved along a conveyor track which is constituted by parallel overhead rails 8 and 9, and from which the shuttering boards are suspended by means of rollers 10 fitted at the ends of one of their long sides.

Arranged parallel to the rails 8 and 9 is a conveyor means which takes the form of a pair of overhead rails 11 which slope downwardly slightly from the horizontal towards station I and on one or the other of which the shuttering boards can be returned one after the other from the deshuttering station IV to the batching station I. To achieve transfer of a shuttering board to the conveyor track, consisting of the two rails 8 and 9 from the overhead rail 11 on which it is located, the rails 11 have a common end portion 12 adjacent to station I, which portion can be swung through 90 by appropriate drive means. The turn-round at station IV is achieved by means of a 90 bend in the two rails 8 and 9 by means of a member 13 which can be selectively aligned with one or other of the rails 11. In this way, the shuttering boards, individually withdrawn from station IV after completion of the deshuttering operation, can be transferred to one or other of the rails 11 along which are locaoted the work areas for the cleaning and preparatory operations. The shuttering boards are then assembled into batches in frames 14 (shown in detail in FIG. 5) and as described below the reference to FIGS. 9 to 11.

Referring to FIG. 5, the frame 14 includes plungers which carry support elements 23, 24, 25 and 26 for inward and outward movement. The elements 23, 24, 25 and 26 are connected to vibrators 27, 28, 29 and 30. Rollers 37 carried by the frame 14 run on vertical rails 38 (see also FIG. 1) which constitute guide means when the frame part 14 is raised and lowered. Frame- ]ifting devices 39 (FIG. 1) are provided for moving the frame part 14 in the vertical direction.

One mode of assembly of the shuttering boards into batches is shown more in detail in FIGS. 9 to 11. The three shuttering boards 37, 38, 39, shown are each connected to tie rods 40, 41; 42, 43; 44, 45; 46, 47 arranged in pairs. For retaining these tie rods, retaining blocks 48, 49 and 50 are provided at each edge of each of the shuttering boards 37, 38, 39. Each retainer block is provided with recesses adapted to cooperate with and retain the tie rods, as seen at 51, 52 (see FIG. 11).

The tie rods 40 to 47 each consist, as illustrated in FIG. 10, of two sleeves 54, 55, displaceable within each other by means of a thread-drive 53, mounting discs 56, 57 being provided on each end for exerting the tension forces.

Between the shuttering boards 37, 38, 39 pivotably joined vertical shuttering boards 58, 59; 60, 61 are provided. The corresponding trays consist of horizontal shuttering boards 62, 63 which are carried by brackets 64, 65 connected to the shuttering boards 38, 39.

As shown in FIG. 6, the heating medium passes through tubular heating ducts 16, open at both ends, extending longitudinally in the shuttering boards 17 and heat is thus distributed in an efficient manner.

The embodiment shown in FIGS. 3 and 4 relates to a form of the apparatus similar to that illustrated in FIGS. 1 and 2 but in which the batches of shuttering boards are arranged longitudinally with respect to the direction of travel. Swinging arms 18 and 19 are provided for transferring the shuttering boards to and from linear conveyor means. The linear conveyor means on which the boards are prepared comprises an overhead rail 11 and a parallel rail 22 connected to the rail 11 through track-switching means 20 and 21. Working stations are disposed along the rail 22 at which the boards can remain for a period of time when more than routine maintainence is required.

FIG. 7 shows a middle section 31, which can be lowered, of the conveyor track constituted by the two parallel rails 8 and 9. The section 31 can be lowered by hydraulic drive means 32 and 33 so as to deposit a batch 2 of shuttering boards on a shaker table 34 connected to vibrating means (not illustrated in the drawing).

FIG. 8 shows a liftable shaker head 35, which is disposed near the pouring station and is connected to vibration means (not shown in the drawing) and which can be raised by means of a lifting device 36 so that it bears against the base of the batch 2 located in the pouring station.

In an alternative arrangement, the liftable frame 14 shown in FIG. 5 can be displaceable on rails between two stations, each station being used interchangeably as a batching station or a station at which pouring or deshuttering is carried out. It is also possible for the frame 14 to be arranged to be lowered from above, so as to engage round a batch of shuttering panels moved below it. Among other things, this results in a desirable short distance of travel for the frame 14.

What I claim is:

1. Apparatus for the batch production of cast slabs, said apparatus comprising:

a plurality of shuttering boards;

a conveyor, means at the start of said conveyor for forming said shuttering boards into batches with the shuttering boards in each batch being disposed vertically in spaced horizontal relation, means at a pouring station of said conveyor for pouring settable material into batches moved sequentially along said conveyor, vibration means for vibrating said batches at said pouring station, said conveyor further comprising a setting zone for batches moved along said conveyor from said pouring station, and a deshuttering station for dismantling each batch after the settable material has set so as to release the case slabs for removal; said vibration means comprising a frame dimensioned to surround a batch of shuttering boards, vibrating devices mounted on said frame, means for moving said vibrating devices into engagement with a batch when surrounded by said frame, and means mounting the frame at the pouring station for vertical movement into surrounding relation to a batch.

2. Apparatus as claimed in claim 1, further compris' at least one return conveyor extending from said deshuttering station to the start of the first mentioned conveyor;

means for transferring shuttering boards individually and in sequence from the deshuttering station to the return conveyor; means for transferring the shuttering boards individually and in sequence from the return conveyor to the start of the first mentioned conveyor; and

said return conveyor including means for transferring therealong said shuttering boards individually, in sequence and in planar alignment with each other and with the longitudinal dimension of said return conveyor.

3. Apparatus as claimed in claim 2, further comprising a bypass conveyor and means for diverting shuttering boards to or bringing boards from said bypass conveyor to said return conveyor.

4. Apparatus as claimed in claim 2, wherein said return conveyor is inclined downwardly from the deshuttering station towards the station in which the first mentioned conveyor starts, whereby manual movement of shuttering boards on said return conveyor is facilitated.

5. Apparatus as claimed in claim 1, whereineach of said shuttering boards has roller means at upper corners thereof for engagement with said conveyor. 

1. Apparatus for the batch production of cast slabs, said apparatus comprising: a plurality of shuttering boards; a conveyor, means at the start of said conveyor for forming said shuttering boards into batches with the shuttering boards in each batch being disposed vertically in spaced horizontal relation, means at a pouring station of said conveyor for pouring settable material into batches moved sequentially along said conveyor, vibration means for vibrating said batches at said pouring station, said conveyor further comprising a setting zone for batches moved along said conveyor from said pouring station, and a deshuttering station for dismantlIng each batch after the settable material has set so as to release the case slabs for removal; said vibration means comprising a frame dimensioned to surround a batch of shuttering boards, vibrating devices mounted on said frame, means for moving said vibrating devices into engagement with a batch when surrounded by said frame, and means mounting the frame at the pouring station for vertical movement into surrounding relation to a batch.
 2. Apparatus as claimed in claim 1, further comprising: at least one return conveyor extending from said deshuttering station to the start of the first mentioned conveyor; means for transferring shuttering boards individually and in sequence from the deshuttering station to the return conveyor; means for transferring the shuttering boards individually and in sequence from the return conveyor to the start of the first mentioned conveyor; and said return conveyor including means for transferring therealong said shuttering boards individually, in sequence and in planar alignment with each other and with the longitudinal dimension of said return conveyor.
 3. Apparatus as claimed in claim 2, further comprising a bypass conveyor and means for diverting shuttering boards to or bringing boards from said bypass conveyor to said return conveyor.
 4. Apparatus as claimed in claim 2, wherein said return conveyor is inclined downwardly from the deshuttering station towards the station in which the first mentioned conveyor starts, whereby manual movement of shuttering boards on said return conveyor is facilitated.
 5. Apparatus as claimed in claim 1, wherein each of said shuttering boards has roller means at upper corners thereof for engagement with said conveyor. 